Selectively illuminable metallic looking trims and their methods of manufacture

ABSTRACT

A trim for an object and its method of manufacture involve providing a transparent or translucent substrate defining a top surface, applying an opaque layer above the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and applying one or more translucent metallic-looking layers above a top surface of the opaque layer. In some implementations, the trim is a selectively illuminable trim whereby a light source is arranged beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-looking layers.

FIELD

The present application generally relates to decorative trims and, moreparticularly, to selectively illuminable metallic looking trims andtheir methods of manufacture.

BACKGROUND

Decorative trims are applied to accent or enhance the visual appearanceof an object. For example, vehicle interior and exterior componentsoften have decorative trims. To further enhance the visual appearance ofa decorative trim, light sources and light guides can be incorporatedinto the decorative trim to generate a lighting effect. Chrome platingis one example of a decorative trim that is often utilized due to itshigh gloss appearance. Chrome plating, however, can have a negativeenvironmental impact, e.g., due to the use of hexavalent chromium baths.Chrome plating is also formed of one or more opaque metallic layers thatdo not allow light to pass through and thus it cannot be used inconnection with back-lit lighting effects. Accordingly, while suchdecorative trims work well for their intended purpose, there remains aneed for improvement in the relevant art.

SUMMARY

According to one aspect of the present disclosure, a trim for an objectis presented. In one exemplary implementation, the trim comprises atransparent or translucent substrate defining a top surface, an opaquelayer applied above the top surface of the substrate, the opaque layerdefining one or more apertures through which light can pass, and one ormore translucent metallic-looking layers applied above a top surface ofthe opaque layer.

In some implementations, the trim further comprises a first translucentbase coat layer applied to the top surface of the substrate, wherein theopaque layer is applied to a top surface of the first translucent basecoat layer. In some implementations, the trim further comprises a secondtranslucent base coat layer applied to the top surface of the opaquelayer and a portion of the top surface of the first translucent basecoat layer corresponding to the one or more apertures, wherein the oneor more translucent metallic-looking layers are applied to a top surfaceof the second translucent base coat layer. In some implementations, thetrim further comprises a top coat layer applied to a top surface of theone or more metallic-looking layers.

In some implementations, the one or more apertures in the opaque layerare formed by pre-deposit masking or post-deposit laser etching. In someimplementations, the one or more apertures in the opaque layer areformed by pre-deposit masking or post-deposit laser etching. In someimplementations, at least the one or more metallic-looking layers areapplied using a physical vapor deposition (PVD) system. In someimplementations, at least the one or more metallic-looking layers areapplied using a painting system.

In some implementations, the trim is a selectively illuminable trim thatfurther comprises a light source arranged beneath a bottom surface ofthe substrate, the light source being configured to output light throughthe substrate, the one or more apertures defined by the opaque layer,and the one or more metallic-looking layers. In some implementations,the trim further comprises a light guide arranged between the lightsource and the bottom surface of the substrate, the light guide beingconfigured to distribute the light output from the light source.

According to another aspect of the present disclosure, a method ofmanufacturing a trim for an object is presented. In one exemplaryimplementation, the method comprises: providing a transparent ortranslucent substrate defining a top surface, applying an opaque layerabove the top surface of the substrate, the opaque layer defining one ormore apertures through which light can pass, and applying one or moretranslucent metallic-looking layers above a top surface of the opaquelayer.

In some implementations, the method further comprises applying a firsttranslucent base coat layer to the top surface of the substrate, whereinthe opaque layer is applied to a top surface of the first translucentbase coat layer. In some implementations, the method further comprisesapplying a second translucent base coat layer to the top surface of theopaque layer and a portion of the top surface of the first translucentbase coat layer corresponding to the one or more apertures, wherein theone or more translucent metallic-looking layers are applied to a topsurface of the second translucent base coat layer. In someimplementations, the method further comprises applying a top coat layerto a top surface of the one or more metallic-looking layers.

In some implementations, the method further comprises one of (i)applying a mask to the top surface of the substrate prior to applyingthe opaque layer, wherein the mask defines the one or more apertures,and (ii) laser etching the opaque layer to form the one or moreapertures. In some implementations, the method further comprises one of(i) applying a mask to the top surface of the first translucent basecoat layer prior to applying the opaque layer, wherein the mask definesthe one or more apertures, and (ii) laser etching the opaque layer toform the one or more apertures. In some implementations, at least theone or more metallic-looking layers are applied using a PVD system. Insome implementations, at least the one or more metallic-looking layersare applied using a painting system.

In some implementations, the trim is a selectively illuminable trim andthe method further comprises arranging a light source beneath a bottomsurface of the substrate, the light source being configured to outputlight through the substrate, the one or more apertures defined by theopaque layer, and the one or more metallic-looking layers. In someimplementations, the method further comprises arranging a light guidebetween the light source and a bottom surface of the substrate, thelight guide being configured to distribute the light output from thelight source.

Further areas of applicability of the teachings of the presentdisclosure will become apparent from the detailed description, claimsand the drawings provided hereinafter, wherein like reference numeralsrefer to like features throughout the several views of the drawings. Itshould be understood that the detailed description, including disclosedembodiments and drawings referenced therein, are merely exemplary innature intended for purposes of illustration only and are not intendedto limit the scope of the present disclosure, its application or uses.Thus, variations that do not depart from the substance of the presentdisclosure are intended to be within the scope of the presentdisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a a defective selectivelyilluminable trim formed via A-side masking of primer layers;

FIGS. 2A-2D are cross-sectional views of different configurations of aselectively illuminable trim according to the principles of the presentdisclosure; and

FIG. 3 is a flow diagram of a method of manufacturing the selectivelyilluminable trim according to the principles of the present disclosure.

DETAILED DESCRIPTION

As discussed above, chrome plating is formed of one or more opaquemetallic layers that do not allow light to pass through, which makes itunusable for decorative trim having back-lit lighting effects. Chromeplating also attenuates radar transmission. Additionally, B-side masking(i.e., applying the opaque layer to a back surface of the substrate) canresult in distortion, particularly when being viewed at an angle.Accordingly, improved selectively illuminable metallic looking trimshaving A-side masking and their methods of manufacture are presented. Inother aspects of the present disclosure, metallic looking trimscomprising multiple stacked layers along with a light source and anoptional light guide are packaged together to form single integratedmodules. In some embodiments, these trims utilize a metallic-lookinglayer or coating and an opaque back layer to achieve a metallic lookingcomponent that is as aesthetically pleasing as chrome plating. In someembodiments, one or more base coat primer layers are applied. Forexample, a first base coat primer layer could be applied between thesubstrate and the opaque layer. An optional second base coat layer couldalso be applied between the opaque layer and the metallic-looking layer.In some embodiments, a top coat layer is applied atop the metalliclooking layer.

Referring now to FIG. 1, a cross sectional view of a defectiveselectively illuminable decorative trim 100 formed via A-side masking ofprimer layers is illustrated. The trim 100 comprises a stack 104 formedof multiple stacked layers. A transparent or translucent substrate 108forms a base of the stack 104. Non-limiting examples of the substrate108 include plastic or polymer materials, such as polycarbonates (PC),polymethyl methacrylates (PMMA), acrylonitrile butadiene styrenes (ABS),styrene acrylics, styrene acrylonitrile polymers, polyamides, andcombinations thereof. For vehicle trim applications, the substrate 108could be an interior component (a dash assembly, a center consoleassembly, a multimedia or infotainment unit assembly, a door trim panel,etc.) or an exterior body component (front or side grille assemblies,bumper or fender accents, head or taillight accents, a trunk lidfinisher, etc.). It will be appreciated that the systems and methodsdescribed herein are not limited to automotive applications and could beapplicable to decorative trims for non-automotive applications(appliances and consumer goods, railway, motorbikes, aerospace, etc.).

An opaque layer 112 is applied to a top surface of the substrate 108.The opaque layer 112, while illustrated as a black primer layer, couldhave any suitable color or composition that prevents or substantiallymitigates light transmission therethrough. Non-limiting examples of theopaque layer 112 comprise epoxy-based, polyurethane-based, andacrylic-based curable wet paints having opaque color pigments andcombinations thereof. The opaque layer 112 defines one or more gaps orapertures 116, formed via pre-deposit masking or post-deposit laseretching, through which light is able to pass. The one or more apertures116 correspond to a designed lighting accent effect, such as, forexample, an accent, logo, indicia, icon, motif, pattern, button, orother similar accent for the object associated with the trim. Atranslucent base coat primer layer 120 is applied to a top surface ofthe opaque layer 112 as well as to the top surface of the substrate 108in areas corresponding to the one or more apertures 116. Non-limitingexamples of the base coat layer 120 include epoxy-based,polyurethane-based, and acrylic-based curable wet paints that aretransparent or translucent and combinations thereof.

One or more translucent metallic-looking layers 124 are applied (e.g.,via physical vapor deposition, or PVD) to a top surface of the base coatlayer 120. It will be appreciated that the term “metallic-looking” asused herein refers to an at least partially transparent layer that looksmetallic or otherwise provides a “metallic effect.” For example, two ormore layers could achieve the optimal aesthetics (base coat layer120+single metallic-looking layer 124, single primer layer 120+twometallic-looking layers 124, two metallic-looking layers 124 and noprimer layer 120, etc.). The metallic-looking layer 124 is translucentbecause it is formed of a material or coating comprising elements thatare translucent (i.e., at least partially light-transmissive) such as,but not limited to, transition metals, post-transition metals,metalloids, and combinations thereof (e.g., alloys, such as oxides andoxide alloys). For example only, the metallic-looking layer could be apaint solution comprising flakes of one or more of the elementsdescribed above or a coating formed via sublimiation of one or more ofthe elements described above via PVD or a similar technique. It will beappreciated that metallic flakes or similar materials could also beincluded in the primer layer 120 to further enhance the metallic look oreffect. The thickness of the metallic-looking layer 124 should be suchthat it remains at least translucent when illuminated by back-lightingwhile also looking metallic when not illuminated. The transluceny of ametallic layer could also be affected by the chemical composition of thelayer and dispersion of elements as reflected.

The metallic-looking layer 124 could also comprise multiple layers of asingle metallic-looking material or different metallic-looking materialsapplied in various stages to achieve the desired optical properties. Anoptional top coat layer 128 could be finally applied to a top surface ofthe metallic-looking layer 124. Non-limiting examples of the top coatlayer 128 include epoxy-based, polyurethane-based, and acrylic-basedcurable wet paints that are transparent or translucent and combinationsthereof. The optional top coat layer 128 could be applied to bothprotect the metallic-looking layer 124 (e.g., from chipping, stripping,or scratching) and/or to further enhance the visual aesthetics of themetallic-looking layer 124 (e.g., by enhancing its glossy appearance).It will be appreciated that the top coat layer 128 could further includemetallic flakes or similar materials to further enhance themetallic-looking of the metallic-looking layer(s) 124. It will also beappreciated that the top coat layer 128 could also be tinted and/orcolored to further enhance this metallic look or effect. Non-limitingexamples of this include a blue metallic-look, a copper metallic-look,and a bronze metallic-look, but any tinting and/or coloring combinationscould be utilized.

The trim 100 further comprises a light source 132 (e.g., alight-emitting diode (LED), organic LED (OLED), optical fiber,electroluminescent, or a similar device, such as a laser light source)and an optional light guide 136 for directing, focusing, or distributingthe light generated from the light source 132 through the substrate 108and the one or more apertures 116 to form a visible field. As shown, adefect 140 occurs due to the aperture 116 formed in the opaque layer112. More particularly, the base coat or primer layer 120 never forms aflush top surface. The resulting defect 140 appears similar to a sinkmark, which propagates through each of the various layers 120, 124, 128.This defect 140 could be perceivable to a human by touch (e.g., on thetop surface of the metallic-looking layer(s) 124 or the top coat 128)and/or by view. For example, the defect 140 could cause a visibledistortion in the visible field projected by the light source 132 andthe optional light guide 136. As a result of this defect 140, thereremains a need for improvement in the manufacture of selectivelyilluminable metallic-looking trims.

Referring now to FIGS. 2A-2D, various configurations of a secondembodiment of a selectively illuminable metallic looking trim 200 areillustrated. The trim 200 comprises a stack 204 formed of multiplestacked layers, which can have the same or similar composition as thelayers of stack 104 in FIG. 1 as described above. In FIG. 2A, a firstbase coat primer layer 212 is applied to the top surface of a substrate208. It will be appreciated, however, that the first base coat layer 212could be optional (see, e.g., FIG. 2B). An opaque layer 216 is thenapplied to either the top surface of the substrate 208 (FIG. 2B) or tothe top surface of the first base coat layer 212 (FIGS. 2A and 2C-2D).The opaque layer 216 defines one or more apertures 220, which could beformed via pre-deposit masking or post-deposit laser etching or anothersuitable process. A second base coat primer layer 218 could optionallybe applied to a top surface of the opaque layer 216 and a portion of thetop surface of the first base coat layer 212 corresponding to the one ormore apertures 220. A metallic-looking layer 224, which could comprisemultiple layers that are sequentially applied, is applied to either, isapplied to either a top surface of the second base coat layer 218 (FIG.2D) or to the top surface of the opaque layer 216 and a portion of thetop surface of the substrate 208 (FIG. 2B) or a portion of the topsurface of the first base coat layer 212 (FIGS. 2A and 2C) correspondingto the one or more apertures 220. A top coat layer 228 is optionallyapplied to a top surface of the metallic-looking layer 224. Detailsregarding the different layer materials and their methods ofapplication, as well as the packaging of the stack 204 with a lightsource 232 and an optional light guide 236 to form a single integratedselectively illuminable trim module, are discussed below. It will alsobe appreciated that the thicknesses of the various layers of stack 204(and stack 104) are not to scale. In one exemplary implementation, thesubstrate thickness is approximately 2-3 millimeters, the base coatthickness is approximately 20 microns, and the opaque andmetallic-looking layer combined thickness is approximately 40-150nanometers.

Referring now to FIG. 3, a flow diagram of a method 300 of manufacturingthe second embodiment of the trim 200 of FIGS. 2A-2D is illustrated. At304, the transparent or translucent substrate 108 is obtained. Thesubstrate 108 could be formed, for example, using any suitable plasticor polymer processing technique including, but not limited to, injectionmolding, extrusion, compression molding, thermoforming, and additivemanufacturing (e.g., three-dimensional (3D) printing). As previouslymentioned, non-limiting examples of the substrate 108 include plastic orpolymer materials, such as PC, PMMA, ABS, styrene acrylics, styreneacrylonitrile polymers, polyamides, and combinations thereof. In oneexemplary implementation, the substrate is a plastic interior componentor exterior body component of a vehicle as previously described herein.At optional 308, base coat primer layer 112 is applied to the topsurface of the substrate 108. As previously mentioned, non-limitingexamples of the base coat layer 120 include epoxy-based,polyurethane-based, and acrylic-based curable wet paints that aretransparent or translucent and combinations thereof. At optional 312,masking is performed. This could include applying a patterned layer thatwill not allow the opaque layer material to adhere, thereby forming theone or more apertures 220. This masking step could be performed, forexample, when laser etching is not being used.

At 316, the opaque layer 216 is applied. As previously discussed, theopaque layer 216 could be applied via PVD, chemical vapor deposition(CVD), a paint application, or another similar technique. At optional320, laser etching is performed to form the one or more apertures 220 inthe opaque layer 216. This laser etching step could be performed, forexample, when masking is not being used. At optional 324, a second basecoat primer layer 218 could be applied to the top surface of the opaquelayer 216 and a portion of the top surface of the first base coat layer212 corresponding to the one or more apertures 220. Non-limitingexamples of the second base coat layer 218 include epoxy-based,polyurethane-based, and acrylic-based curable wet paints that aretransparent or translucent and combinations thereof. At 328, themetallic-looking layer 224 is applied. In some embodiments, themetallic-looking layer 224 and the one or more base coat layers 212, 218are applied by a PVD system. In one exemplary implementation, the PVDsystem is a magnetron sputtering system. At optional 332, the top coatlayer 228 is applied. As previously mentioned, non-limiting examples ofthe top coat layer 128 include epoxy-based, polyurethane-based, andacrylic-based curable wet paints that are transparent or translucent andcombinations thereof. In some implementations, the top coat layer 228 isformed such that it has a substantially flush top surface (see, e.g.,FIG. 2B). Steps 336 and 340 relate to the packaging of the stack 204, alight source 232, and an optional light guide 236 into a singleintegrated module.

The techniques of the present disclosure provide other benefits beyondthe elimination of the A-side masking defect illustrated in FIG. 1.These techniques allow for better matching to the appearance ofnon-translucent or opaque PVD applications. This is because atraditional translucent PVD stack is not as bright as a non-translucentor opaque PVD stack. One example non-translucent or opaque PVD stack isa chrome plated trim component, such as on a vehicle. Thus, thesetechniques allow for better matching of the resulting translucent,metallic-looking components to such chrome plated components.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known procedures,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The term “and/or” includes any and all combinations of one ormore of the associated listed items. The terms “comprises,”“comprising,” “including,” and “having,” are inclusive and thereforespecify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof. The method steps,processes, and operations described herein are not to be construed asnecessarily requiring their performance in the particular orderdiscussed or illustrated, unless specifically identified as an order ofperformance. It is also to be understood that additional or alternativesteps may be employed.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

It should be understood that the mixing and matching of features,elements, methodologies and/or functions between various examples may beexpressly contemplated herein so that one skilled in the art wouldappreciate from the present teachings that features, elements and/orfunctions of one example may be incorporated into another example asappropriate, unless described otherwise above.

What is claimed is:
 1. A trim for an object, the trim comprising: atransparent or translucent substrate defining a top surface; an opaquelayer applied above the top surface of the substrate, the opaque layerdefining one or more apertures through which light can pass; and one ormore translucent metallic-looking layers applied above a top surface ofthe opaque layer.
 2. The trim of claim 1, further comprising a firsttranslucent base coat layer applied to the top surface of the substrate,wherein the opaque layer is applied to a top surface of the firsttranslucent base coat layer.
 3. The trim of claim 2, further comprisinga second translucent base coat layer applied to the top surface of theopaque layer and a portion of the top surface of the first translucentbase coat layer corresponding to the one or more apertures, wherein theone or more translucent metallic-looking layers are applied to a topsurface of the second translucent base coat layer.
 4. The trim of claim3, further comprising a top coat layer applied to a top surface of theone or more metallic-looking layers.
 5. The trim of claim 1, furthercomprising a top coat layer applied to a top surface of the one or moremetallic-looking layers.
 6. The trim of claim 2, further comprising atop coat layer applied to a top surface of the one or moremetallic-looking layers.
 7. The trim of claim 1, wherein the one or moreapertures in the opaque layer are formed by pre-deposit masking orpost-deposit laser etching.
 8. The trim of claim 2, wherein the one ormore apertures in the opaque layer are formed by pre-deposit masking orpost-deposit laser etching.
 9. The trim of claim 1, wherein at least theone or more metallic-looking layers are applied using a physical vapordeposition (PVD) system.
 10. The trim of claim 1, wherein at least theone or more metallic-looking layers are applied using a painting system.11. The trim of claim 1, wherein the trim is a selectively illuminabletrim that further comprises a light source arranged beneath a bottomsurface of the substrate, the light source being configured to outputlight through the substrate, the one or more apertures defined by theopaque layer, and the one or more metallic-looking layers.
 12. The trimof claim 11, further comprising a light guide arranged between the lightsource and the bottom surface of the substrate, the light guide beingconfigured to distribute the light output from the light source.
 13. Amethod of manufacturing a trim for an object, the method comprising:providing a transparent or translucent substrate defining a top surface;applying an opaque layer above the top surface of the substrate, theopaque layer defining one or more apertures through which light canpass; and applying one or more translucent metallic-looking layers abovea top surface of the opaque layer.
 14. The method of claim 13, furthercomprising applying a first translucent base coat layer to the topsurface of the substrate, wherein the opaque layer is applied to a topsurface of the first translucent base coat layer.
 15. The method ofclaim 14, further comprising applying a second translucent base coatlayer to the top surface of the opaque layer and a portion of the topsurface of the first translucent base coat layer corresponding to theone or more apertures, wherein the one or more translucentmetallic-looking layers are applied to a top surface of the secondtranslucent base coat layer.
 16. The method of claim 15, furthercomprising applying a top coat layer to a top surface of the one or moremetallic-looking layers.
 17. The method of claim 13, further comprisingapplying a top coat layer to a top surface of the one or moremetallic-looking layers.
 18. The method of claim 14, further comprisingapplying a top coat layer to a top surface of the one or moremetallic-looking layers.
 19. The method of claim 13, further comprisingone of (i) applying a mask to the top surface of the substrate prior toapplying the opaque layer, wherein the mask defines the one or moreapertures, and (ii) laser etching the opaque layer to form the one ormore apertures.
 20. The method of claim 14, further comprising one of(i) applying a mask to the top surface of the first translucent basecoat layer prior to applying the opaque layer, wherein the mask definesthe one or more apertures, and (ii) laser etching the opaque layer toform the one or more apertures.
 21. The method of claim 13, wherein atleast the one or more metallic-looking layers are applied using aphysical vapor deposition (PVD) system.
 22. The method of claim 13,wherein at least the one or more metallic-looking layers are appliedusing a painting system.
 23. The method of claim 13, wherein the trim isa selectively illuminable trim and the method further comprisesarranging a light source beneath a bottom surface of the substrate, thelight source being configured to output light through the substrate, theone or more apertures defined by the opaque layer, and the one or moremetallic-looking layers.
 24. The method of claim 23, further comprisingarranging a light guide between the light source and a bottom surface ofthe substrate, the light guide being configured to distribute the lightoutput from the light source.